Fixture support system and method

ABSTRACT

A device comprising a chassis, which may be formed with a strut and a hollow housing, the chassis having a groove disposed at an end for receiving a cross member such that the cross member is slidable within the groove. Some embodiments may have a plurality of suspension wires, said suspension wires coupled to the cross member to provide support for the fixture. Some embodiments may have rotatable hubs connected to the cross member, the hub for providing support for a light source attached to the hub. Some embodiments may provide for a ballast disposed into the housing.

This patent application claims the benefit of U.S. Provisional PatentApplication No. 61/229,463, entitled “Luminaire System and Method” filedJul. 29, 2009 by the inventors George Mieling, Thomas Warton and ScottS. Yu.

The present invention relates generally to fixture supports, and moreparticularly to a system and method for mounting electrical and lightingfixtures to a support structure.

BACKGROUND

Lighting and electrical fixture system designs are driven by newtechnologies and by demands for more efficiency from the market. Thesedemands include economic concerns governing the price and operationalcosts of the system and other concerns such as environmental issues thatinfluence consumer buying behaviors. To meet these demands fixturedesigners attempt to control costs by creating reusable components thatprovide for multiple uses of a same or similar component. Reusabilityprovides for economies of scale during manufacturing of the systemelements. Additionally, reusable components reduce installation costsbecause, once standardized, people installing the fixture do not needadditional training.

For industrial environments, one consumer demand may be for modularitybecause modular systems often have lower overall costs and allowconsumers of the product the ability to make modifications even after asystem is installed. In addition, modularity may provide for “on thefly” adjustments to meet last minute consumer requirements. Theserequirements may include the ability to rearrange an office or workspacesetting in response to changes in the needs of the organization.

The rising costs of labor also drive lighting fixture design. If costscan be reduced by reducing the cost of installing a fixture, then amanufacturer would have an economic advantage because, all things beingequal, the fixture that costs less to install would be a better bargainfor the customer.

Lighting fixture designers strive to meet changing demands byincorporating new technologies and modern aesthetics into fixturedesigns. As such, what is needed is a cost effective modular lightingfixture that provides for ease of installation.

SUMMARY

Disclosed herein is a device comprising a chassis, which may be formedwith a strut and a hollow housing, the chassis having a groove disposedat each end for receiving a cross member such that the cross member isslidable within the groove, a plurality of suspension wires, saidsuspension wires coupled to the cross member for providing support forthe fixture. Rotatable hubs may be connected to the cross members, eachhub provides support for a light source attached to the hub. Someembodiments provide for a ballast disposed into the housing.

The construction and method of operation of the invention, however,together with additional objectives and advantages thereof will be bestunderstood from the following description of specific embodiments whenread in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a fixture support system.

FIG. 2 shows a coupling device for use in a luminaire system

FIG. 3 illustrates a partially disassembled luminaire system.

FIG. 4 shows an assortment of light rails that may be used with aluminaire system.

DESCRIPTION Generality of Invention

This application should be read in the most general possible form. Thisincludes, without limitation, the following:

References to specific techniques include alternative and more generaltechniques, especially when discussing aspects of the invention, or howthe invention might be made or used.

References to “preferred” techniques generally mean that the inventorcontemplates using those techniques, and thinks they are best for theintended application. This does not exclude other techniques for theinvention, and does not mean that those techniques are necessarilyessential or would be preferred in all circumstances.

References to contemplated causes and effects for some implementationsdo not preclude other causes or effects that might occur in otherimplementations.

References to reasons for using particular techniques do not precludeother reasons or techniques, even if completely contrary, wherecircumstances would indicate that the stated reasons or techniques arenot as applicable.

Furthermore, the invention is in no way limited to the specifics of anyparticular embodiments and examples disclosed herein. Many othervariations are possible which remain within the content, scope andspirit of the invention, and these variations would become clear tothose skilled in the art after perusal of this application.

Lexicography

Read this application with the following terms and phrases in their mostgeneral form. The general meaning of each of these terms or phrases isillustrative, not in any way limiting.

The term “luminaire” generally refers to a lighting fixture which mayinclude one or more of: a light source or lamp, a reflector fordirecting the light, an aperture (with or without a lens), an outershell or housing for lamp alignment and protection, an electricalballast, if required, and a connection to a power source.

The term “fixture” generally means a device for physically supporting anelectrical component such as a luminaire, switch assembly, electricaloutlet or other like devices.

The terms “light rail” and “rail” generally mean an elongated memberhaving a one or more connections for connecting to a light source.

The terms “light”, “lamp” and “light source” generally mean a devicecapable of providing energy in the visible or near-visible energyspectrum. Examples include but are not limited to: incandescent lamps,fluorescent lamps, LEDs and chemiluminescent devices.

DETAILED DESCRIPTION

Specific examples of components and arrangements are described below tosimplify the present disclosure. These are, of course, merely examplesand are not intended to be limiting. In addition, the present disclosuremay repeat reference numerals and/or letters in the various examples.This repetition is for the purpose of simplicity and clarity and doesnot in itself dictate a relationship between the various embodimentsand/or configurations discussed.

Elements

FIG. 1 illustrates fixture support system. In the FIG. 1 a luminaireassembly 100 is depicted suspending from an overhead. The suspensionassembly 110 includes both a structural cable, together with anelectrical power cable 120. It is connected to a chassis 114 which mayprovide an enclosure for an electrical ballast (not shown). One end ofthe chassis 114 is attached to a support arm 116, and the chassis 114may have an additional support arm 126. The support arm 116 is slidablycoupled to the chassis 114 such that the support arm 116 can be adjustedin relationship to the chassis 114. Likewise a support arm 126 isslidably coupled to the chassis to allow it to move for betterpositioning. Depending on the length of the chassis 114 many othersupport arms can be added in series. The support arms are cross membersin relation to the chassis 114. Slidable coupling may be effectuatedusing set screws or other mechanisms to allow for sliding of the armsand then locking them in place once set.

The chassis 114, the support arm 116 and other parts of the fixturesupport system described below may be formed by available processes,including, but not limited to: extrusion, molding or machining. Thematerial may be any suitable material providing sufficient strength andother properties, including but not limited to: aluminum, steel,ceramics or plastics.

The support arms 116, 126, (and others) are designed to hold in placelight rails 118. The light rails as shown in the FIG. 1 include areflector formed to direct light towards a particular direction andconnectors such as sockets and plugs for connecting to a light source.The light source may be electrically coupled to a power source throughthe power cable 120. The light rails 118 are connected to the supportarms by hub assemblies 124. The light rails 118 are designed to protecta lighting device and may include clear shields, baffles and otherstructures effectuating a similar result. The hub assembly 124 allowsfor rotation of the light rails 118, thus allowing users to configurethe direction of the light from the light rails 118. The hub assembly124 provides for a single light rail, and may be paired with another hubassembly 128 to allow for a single support arm 126 to provide formultiple light rails. The hub assemblies 124 also provide for couplingelectrical power from the support arms to the light rail and itsassociated lighting device.

The suspension assembly 110 is coupled to two suspension wires 112 whichmay be formed from a single wire, joined to the suspension assembly 110thus having two separate tensions. A coupling device 122 provides forcoupling the suspension wires 112 to the suspension assembly 110 and forthe adjustment of the suspension wires 112. The coupling devices 122secure suspension wires 112 to the suspension assembly 110 using afastener such as a set screw (not shown). The coupling device 122 allowsfor height adjustment on the suspension assembly 110, and a lateraladjustment on the suspension wires 112.

In the FIG. 1 power to the luminaire is supplied along the suspensionassembly 110 and to the power wire 120 into the chassis 114. From thechassis 114 power can be applied to the light rails 118 in severaldifferent ways. Power can be routed through the arms 116 and 126 andassociated hubs to reach each end of the light rail 118. Or power couldbe routed through one of the arms 116 or 126 to reach a single end ofthe light rail 118, having an additional power line run through thelight rail to reach the other end of a lighting device located insidethe light rail 118. The lighting device may be either incandescent,fluorescent or LED Assembly and the like.

In operation an assembler would suspend the fixture using the suspensionassembly 110. After the fixture is suspended, adjusting the couplingdevice 122 and the support arms 116 and 126, to true the entire fixture.This allows for easy installation because variations in the installationcan be easily rectified simply by adjusting the support arms 116 and 126and the coupling device 122. In addition, multiple fixtures such as theone shown in the FIG. 1 maybe suspended side-by-side. By adjusting thecoupling device 122 and the support arms 116 and 126, the fixtures canbe trued to each other.

Coupling Device

FIG. 2 shows a coupling device 200 for use in a luminaire system. Thecoupler 214 may be manufactured from any solid material capable ofhandling the stress depending on the application, preferably a metalsuch as steel or aluminum. The coupler 214 has a bore through one axiswere a cable 210 is passed through the coupling device 200. A set screw218 (or similar fastener) is disposed through the coupler 214 to exertpressure on the cable 210 to lock the coupler 214 in place on the cable210. The coupler 214 must be capable of withstanding threading to allowthe set screw 218 to function properly and secure the cable 210.

The coupler 214 has a second bore offset from the first bore foraccommodating a cable 212. The second cable is secured by the set screw216. In operation, the coupler 214 allows for relative positioning oftwo cables in close proximity and for easy adjustment and alignment ofthe two cables 210 and 212 in relation to each other.

References in the specification to “one embodiment”, “an embodiment”,“an example embodiment”, etc., indicate that the embodiment describedmay include a particular feature, structure or characteristic, but everyembodiment may not necessarily include the particular feature, structureor characteristic. Moreover, such phrases are not necessarily referringto the same embodiment. Further, when a particular feature, structure orcharacteristic is described in connection with an embodiment, it issubmitted that it is within the knowledge of one of ordinary skill inthe art to affect such feature, structure or characteristic inconnection with other embodiments whether or not explicitly described.Parts of the description are presented using terminology commonlyemployed by those of ordinary skill in the art to convey the substanceof their work to others of ordinary skill in the art.

FIG. 3A illustrates a partially disassembled luminaire system. In theFIG. 3A a luminaire assembly 300 is depicted suspended from an overheadmount. The suspension assembly 310 includes both a structural cable,together with an electrical power cable 320. The suspension assembly 310is connected to a strut 324 which acts as a chassis for connecting to aballast housing 314. One having skill in the art would recognize that achassis may be formed without a housing and that t ballast housing 314need not contain a ballast to effectuate some embodiments. One end ofthe ballast housing is attached to a support arm 316, and the ballasthousing 314 may be connected to an additional support arm 326. Thesupport arm 316 is slidably coupled to the ballast housing 314 throughthe use a groove positioned on an end of the ballast housing 314 suchthat the support arm 316 is placed in the groove and can slide todifferent positions in the groove. The support arm 316 can be adjustedin relationship to the ballast housing 314. Likewise a support arm 326is slidably coupled to the ballast housing to allow it to move forbetter positioning. Depending on the length of the ballast housing 314many other support arms can be added in series. Slidable coupling may beeffectuated using set screws or other mechanisms to allow for sliding ofthe arms and then locking them in place once set in position.

Ballast in Arm

One having skill in the art will appreciate that the ballast housing 314may be alternatively designed to allow for more structural support. Bylocating a ballast into the support arm 316 or 326, the ballast housingmay need to be manufactured from material having different strengthcharacteristics or shaped differently from that show in the FIG. 3A.Relatively small ballasts are commercially available (B & L ModelNU6-1128-MSN/D for example) and support arms may be manufactured tocompletely house the ballast. A modified strut may be added to theballast housing 314, or if the ballast is located in a support arm or ifa ballast is not needed, a modified strut may replace the ballasthousing 314.

Shelf Mount

Some embodiments of a fixture support system may be effectuated withoutsuspending from an overhead. For example the chassis may be mounted tothe top of shelving of other structures such that a light rail willproject outward providing light. Using a bookshelf as an example, thechassis may be mounted across the top of a bookshelf such that thesupport arms 316 and 326 extend outward form the shelves. This wouldallow for an adjustable light for person looking at the books or otheritems on the shelves. For a shelf installation, the support arms mayextend out in two directions providing light for shelves on the oppositesides of a structure, or in the alternative, the support arms 316 and326 may be formed to only extend from the chassis in one direction.

Enhanced Strut

FIG. 3B shows a support which may be used as a chassis for effectuatinga fixture. The support 350 may be formed from conventionally available“strut channel” often used in construction. Added to the strut channelsupport 350 is a member 352 extending along the length of the strutchannel support 350. The member 352 has the affect of strengthening thestrut channel support 350 and reducing the effects of bending, torsionalor twisting forces on the support 350. The support 350 may be formed toany desired length, and the member 352 may be welded on or optionallyextruded when formed. Also, the member need not be continuous, but maybe formed from several pieces positioned about the support 350 toachieve the desired result.

The support arms 316, 326, (and others, not shown) are designed to holdin place light rails. The suspension assembly 310 is coupled to twosmaller suspension wires 312 which may be a single wire. The wires 312are fastened to the support arm 316, but alternatively, the ends of thewires may be formed as a catch, with the affect of allowing the ends ofthe wires 312 to be disposed into a “key hole.” The key hole formed witha larger portion for accepting the catch and a smaller portion forholding the catch in place. A coupler 322 provides for the adjustment ofthe suspension wires 312 and secures them in place with a set screw (notshown). The coupler 322 allows for height adjustment on the suspensionassembly 310, and a lateral adjustment on the suspension wires 312.

Power to the luminaire is supplied along the suspension assembly 310 andto the power wire 320 then into the ballast housing 314. From theballast housing 314 power can be applied to the light rails in severaldifferent ways. Power can be routed through the arms 316 and 326 toreach each end of a light rail. Or power could be routed through one ofthe arms 316 or 326 to reach a single end of a light rail having anadditional power line run through the light rail to reach the other endof a lighting device located inside the light rail if necessary.

In operation, an assembler would suspend the luminaire using thesuspension assembly 310. After the luminaire is suspended, adjusting thecoupler 322 and the support arm swing 316 and 326, to true the entireassembly. This allows for easy installation because minor variations inthe installation can be easily rectified simply by adjusting the supportarms 316 and 326 and the coupler 312.

FIG. 4 shows an assortment of light rails 400 that may be used with aluminaire system. In the FIG. 4 a baffle 410 provides for a coveringover a light source that has the effect of allowing light out of therail, but reducing glare when viewed from a side angle. The baffle 410may be manufactured from semi-rigid material such that the baffle 410snaps into the light rail and is thus held securely by compression.Alternatively, a baffle may be fastened in place by coupling it to thelight rail using conventional fasteners such as screws and bolts. Thebaffle 410 as shown includes structure 414 to secure the baffle to anelongated lamp thus allowing the baffle 410 to hang suspended form thelamp.

The baffle 410 may be constructed to effectuate different lightprojections from the lighting element and may be designed for particularlight sources. For example a baffle may be designed for LED lightingwhich often has multiple discrete light sources as compared to afluorescent lamp which has a continuous illuminate throughout the lengthof the bulb.

In a luminaire system different light rails may be employed by couplingthem to a hub 412, such that the hub provides mechanical support,pivotability and a means to provide the light source with electricalpower.

The above illustration provides many different embodiments orembodiments for implementing different features of the invention.Specific embodiments of components and processes are described to helpclarify the invention. These are, of course, merely embodiments and arenot intended to limit the invention from that described in the claims.

Although the invention is illustrated and described herein as embodiedin one or more specific examples, it is nevertheless not intended to belimited to the details shown, since various modifications and structuralchanges may be made therein without departing from the spirit of theinvention and within the scope and range of equivalents of the claims.Accordingly, it is appropriate that the appended claims be construedbroadly and in a manner consistent with the scope of the invention, asset forth in the following claims.

What is claimed is:
 1. A device comprising: a chassis, said chassishaving a groove disposed at a first end and a second groove disposed ata second end, and a cross member slidably disposed in the groove at thefirst end.
 2. The device of claim 1 further comprising: a plurality ofsuspension wires, said suspension wires coupled to the cross member. 3.The device of claim 1 further including a rotatable hub connected to thecross member, and a light rail coupled to the rotatable hub.
 4. Thedevice of claim 3 wherein the cross member is hollow and a wire isdisposed within the cross member between the chassis and the hub.
 5. Thedevice of claim 1 wherein the chassis comprises a housing and a strut.6. The device of claim 5 wherein the housing further includes a ballastdisposed within the housing.
 7. The device of claim 1 wherein the crossmember is formed with a key slot and the suspension wires are formedwith a catch, said catch operable to mate with the key slot.
 8. Thedevice of claim 1 further including: a coupler, said coupler having athrough hole creating a passage from a first side of the coupler to asecond side of the coupler, and said coupler having a threaded hole,said threaded hole disposed substantially orthogonally to the passagecreated by the through hole and extending from an interior point in thepassage to the exterior of the coupler.
 9. A method comprising:suspending a chassis from a structure, said chassis having a firstgroove disposed on a first end and a second groove disposed along asecond end opposite the first end; disposing a first cross arm in thefirst groove and a second cross arm in the second groove, wherein thefirst and second cross arm are slidable in their respective grooves;coupling a plurality of wires in the each cross arm, wherein the crossarms are supported by the plurality of wires.
 10. The method of claim 9further including: attaching a hub to a cross arm and disposing a wirefrom the hub, through an interior passage of the cross arm.
 11. Themethod of claim 9 further including: adjusting the position of the crossarms with respect to the chassis.